JP2018161897A - Creation of three-dimensional object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce interruption frequency or time delay between continuous print jobs in a lamination molding system.SOLUTION: Provide is a molding module. The molding module may sometimes include a molding material chamber installed in a housing for maintaining the housing and a molding material. The molding module may sometimes include a molding chamber installed in the housing. The molding material chamber may sometimes be located below or next to the molding chamber. The molding chamber may sometimes include a movable support member for receiving continuous layers of the molding material from a molding material feeding device. The molding module can be removably inserted into a molding receiver of a lamination molding system, thereby the lamination molding system can harden a part of the continuous layers received on the movable support member.SELECTED DRAWING: Figure 1a

Description

RELATED APPLICATION This application claims benefits based on PCT Application No. PCT / US2014 / 014025 entitled “GENERATING THREE-DIMENSIONAL OBJECTS” filed on January 31, 2014, the entire contents of this PCT application. Are hereby incorporated by reference. This PCT application itself claims the benefit of PCT application No. PCT / EP2014 / 050841, entitled “GENERATING THREE-DIMENSIONAL OBJECTS” filed on January 16, 2014. The entire contents of the application are incorporated herein by reference.

  An additive manufacturing system that generates three-dimensional objects one by one has been proposed as a method that may be convenient for manufacturing only a small amount of three-dimensional objects.

  The quality of objects produced by such systems may vary widely depending on the type of additive manufacturing technique used. In general, the lower the cost of the system, the lower the quality and the strength of the object can be produced. The higher the cost of the system, the higher the quality and strength of the object.

  Some examples are described with reference to the following drawings.

FIG. 6 is a simplified schematic diagram illustrating a shaping module for generating a three-dimensional object, according to some examples. FIG. 6 is a simplified schematic diagram illustrating a shaping module for generating a three-dimensional object, according to some examples. FIG. 6 is a simplified schematic diagram illustrating a shaping module for generating a three-dimensional object, according to some examples. 1 is a simplified perspective view of an additive manufacturing system, according to some examples. FIG. FIG. 6 is a simplified perspective view showing a removable modeling module for an additive manufacturing system, according to some examples. FIG. 6 is a simplified perspective view showing a removable modeling module for an additive manufacturing system, according to some examples. FIG. 6 is a simplified perspective view illustrating a shaping assembly of a shaping module, according to some examples. FIG. 6 is a simplified side view illustrating a shaping assembly of a shaping module, according to some examples. FIG. 2 is a simplified perspective view showing an additive manufacturing system after receiving a removable modeling module, according to some examples. FIG. 2 is a simplified perspective view showing an additive manufacturing system after receiving a removable modeling module, according to some examples. FIG. 6 is a simplified perspective view showing a removable modeling module for an additive manufacturing system, according to some examples. FIG. 6 is a simplified side view illustrating a graphic assembly of a shaping module, according to some examples. FIG. 6 is a flow diagram illustrating a method for a three-dimensional object according to some examples. FIG. 3 shows one of a series of side cross-sectional views showing various layers of build material, according to some examples. FIG. 3 shows one of a series of side cross-sectional views showing various layers of build material, according to some examples. FIG. 3 shows one of a series of side cross-sectional views showing various layers of build material, according to some examples. FIG. 3 shows one of a series of side cross-sectional views showing various layers of build material, according to some examples.

    The following terms are to be interpreted as meaning the following, as described in the specification or claims. The singular forms “a”, “an”, and “the” mean “one or more”. The terms “including” and “having” are intended to mean the same “inclusion” as “comprising”.

  With an additive manufacturing system, a three-dimensional object can be generated by curing various portions of one or more successive layers of modeling material. The build material may be in powder form and the nature of the object produced may depend on the type of build material and the type of curing means used. In some examples, curing may be performed using a liquid binder to chemically cure the build material. In other examples, curing may be performed by temporary application of energy to the build material. This may include, for example, the use of coalescing aids. The coalescing aid is a material that can combine and cure the modeling material when an appropriate amount of energy is applied to the combination of the modeling material and the coalescing aid.

  However, some additive manufacturing systems may not have sufficient degrees of freedom and speed in design, for example. For example, if the build material requires replenishment or the system requires cleaning, it can be difficult to maintain print continuity. There may also be a time delay between print jobs. Further, in some examples, such systems may require advanced user intervention in design, such as handling and cleaning of build materials.

  Accordingly, the present disclosure provides various modeling modules that can be removably inserted into an additive manufacturing system. Modular design may provide versatility, for example, by allowing the insertion of different types of build modules, such as different size and / or multiple build modules, at a time. . Also, the modular design allows for continuous print jobs to be completed in a system, for example, allowing a complete print job to be completed with little or no time delay between print jobs. High productivity can be achieved by allowing faster use in use and fewer interruptions. The modeling module may include a housing, and the housing may be provided with a modeling chamber, a modeling material chamber, and / or a motor for moving the chambers. This design may allow for faster cleaning of the modeling module when the modeling module is removed. The modeling module may be easily insertable and removable from the additive manufacturing system.

  FIG. 1 a is a simplified diagram illustrating a shaping module 10 according to some examples. The modeling module 10 may include a housing 12 and a modeling material chamber 14 provided in the housing 12 to hold the modeling material. The modeling module may include a modeling chamber 16 provided in the housing 12. The modeling material chamber 14 may be below the modeling chamber 16. The modeling chamber 16 may include a movable support member 18 for receiving a continuous layer of modeling material from a modeling material supplier. The build module 10 can be removably inserted into a build receiver of the additive manufacturing system so that the additive manufacturing system can receive one of those successive layers received on the movable support member 18. The part can be cured.

  FIG. 1 b is a simplified diagram of a shaping module 50 according to some examples. The modeling module 50 may include a housing 52 and a modeling material chamber 54 provided in the housing 52 to hold the modeling material. The modeling module 50 may include a modeling chamber 56 provided in the housing 52. The modeling chamber 56 includes a movable support member 58 for receiving a continuous layer of modeling material from a modeling material supplier. The modeling module 50 may include a computer readable medium 60 in the housing 52. The computer readable medium 60 may include modeling module data 62 that represents the characteristics of the modeling module 50. The build module 50 can be removably inserted into the build volume of the additive manufacturing system so that the additive manufacturing system can receive one of those successive layers received on the movable support member 58. The part can be cured.

  FIG. 1 c is a simplified diagram illustrating a shaping module 100 according to some examples. The modeling module 100 may include a housing 102 and a modeling material chamber 104 provided in the housing 102 for holding a modeling material. Each modeling module 100 may include a modeling chamber 106 provided in the housing 102. Each modeling chamber 106 may include a movable support member 108 for receiving a continuous layer of modeling material from a modeling material supplier. The modeling module 100 can be removably inserted into the modeling capacity of the additive manufacturing system simultaneously with another such modeling module, whereby the additive manufacturing system is placed on the movable support member 18. It is possible to cure some of those consecutive layers received.

  FIG. 2a is a simplified perspective view showing additive manufacturing system 200, according to some examples. The additive manufacturing system 200 may include a housing 202. As will be described in detail later, the housing 202 may contain various components, such as a drug dispenser and other components.

  The housing 202 may include a side housing portion 204, a central housing portion 206, and a back housing portion 208. The surface of these housing elements can define a shaped receiver 212 that includes a receiving volume. Although FIG. 2a shows a cubic shaped receiving volume 212, in other examples, the receiving volume may have other shapes depending on the configuration and shape of the side housing portion 204, the central housing portion 206, and the back housing portion 208. May have. As shown in FIG. 2a, the central housing portion 206 and the receiving volume 212 extend to a sufficient length along the y-axis direction so that the additive manufacturing system 200 can be considered a wide-type system. There is a case. In other examples, the central housing portion 206 and the receiving volume 212 may have a shorter length or a longer length along the y-axis direction. That is, in some examples, system 200 may be a smaller desktop system.

  The additive manufacturing system 200 may include a system controller 256, which may include a processor 258 for executing various instructions described herein in various manners. . The processor 258 may be, for example, a microprocessor, microcontroller, programmable gate array, application specific integrated circuit (ASIC), computer processor, and the like. The processor 258 may include, for example, multiple cores on a single chip, multiple cores across multiple chips, or a combination thereof. In some examples, processor 258 may include at least one integrated circuit (IC), other control logic, other electronic circuitry, or a combination thereof.

  Controller 256 allows direct user interaction. For example, the system 200 can include various users connected to the processor 258, such as one or more of a keyboard, touchpad, buttons, keypad, dial, mouse, trackball, card reader, or other input device. May include input devices. Further, the system 200 is connected to a processor 258, such as one or more of a liquid crystal display (LCD), a printer, a video monitor, a touch screen display, a light emitting diode (LED), or other output device. Various output devices may be included.

  The processor 258 can communicate with the computer readable storage medium 260 via a communication bus. Computer readable storage media 260 may include a single media or multiple media. For example, computer readable storage medium 260 may include one or both of ASIC memory and individual memory in controller 256. The computer readable storage medium 260 may be any electrical, magnetic, optical, or other physical storage device. For example, the computer readable storage medium 260 may be, for example, random access memory (RAM), static memory, read only memory, electrically erasable programmable read only memory (EEPROM), hard disk drive, optical It may be a drive, storage drive, CD, DVD or the like. The computer readable storage medium 260 may be non-transitory (fixed). Various computer-executable instructions 264 may be stored, encoded, or retained on computer-readable storage medium 260, such that, when executed by processor 258, processor 258. Can perform any one or more of the methods or acts disclosed in accordance with various examples herein.

  2b-2c are simplified perspective views illustrating a removable modeling module 214 for additive manufacturing system 200, according to some examples. The modeling module 214 may include a housing 216. A wheel 218 may be attached to the bottom surface of the housing 216 so that the modeling module 214 can be rolled like a truck. Alternatively, a fixed foot may be provided instead of the wheel. However, in some examples, nothing may be attached to the wheel 218 or the foot. A cover 222 may be removably coupled to the housing 216 to form a portion of the upper surface of the build module 214. As shown in FIG. 2b, removal of the cover 222 exposes the build assembly 224, which may be contained in the housing 216. FIG. 2 c shows the cover 222 attached. The housing 216 and the cover 222 can prevent the modeling material from leaking from the modeling module 214.

  As shown in FIG. 2 c, the build assembly 224 can be removed from the housing 216 by a user using a handle 220 attached to the side of the build assembly 224. Additional handles may be provided on the surface of the modeling assembly 224. In other examples, when the user makes an input, such as pressing a button on the housing 216, build assembly 224, or system 200, the drawer may be automatically and / or electrically used. May open automatically.

  2d-2e illustrate a simplified perspective view and a simplified side view, respectively, of a build assembly 224 of the build module 214, according to some examples. As shown, the build assembly 224 has been completely removed from the housing 216. The modeling assembly 224 may include a modeling material chamber 226 and a modeling chamber 228.

  A support member 230 may be provided in the modeling material chamber 224. A piston 232 may be attached to the bottom surface of the support member 230. The piston 232 is driven by the motor 234 and can move the support member 230 along the z-axis. Similarly, the modeling chamber 228 may be provided with a support member 236. A piston 238 may be attached to the bottom surface of the support member 236. The piston 238 is driven by the motor 240 and can move the support member 236 along the z-axis. In one example, support members 230 and 236 may have dimensions ranging from about 10 cm × 10 cm to 100 cm × 100 cm. In other examples, support members 230 and 236 may have larger or smaller dimensions.

  FIG. 2 e shows the modeling material 246 stored on the upper surface of the support member 230 of the modeling material chamber 226. FIG. 2 e further shows a layer 248 of build material previously deposited on the upper surface of the support member 238 of the build chamber 228. The previously deposited build material 248 includes a portion 250 that is processed using the additive manufacturing system 200 and cured as part of a three-dimensional object.

  In some examples, the modeling material may be a powder modeling material. In this specification, the powder material has a meaning including both dry powder material and wet powder material, particulate material, and granular material. In some examples, the build material may include a mixture of air and solid polymer particles, for example at a ratio of about 40% air to about 60% solid polymer particles. One suitable material is, for example, nylon 12 commercially available from Sigma Aldrich. Another suitable nylon 12 material includes PA2200, commercially available from Electro Optical Systems (EOS). Other examples of suitable modeling materials include, for example, powder metal materials, powder composite materials, powder ceramic materials, powder glass materials, powder resin materials, and powder polymer materials. However, the examples described herein should not be construed as limited to powder materials or any of the materials listed above. In some examples, the modeling material may be a paste or a gel. According to one example, a suitable modeling material may be a powdered semi-crystalline thermoplastic material.

  The build assembly 224 may include a build material supplier 242 such as, for example, a wiper blade or roller. The modeling material supplier 242 is driven by a motor 244 and may supply and / or deposit a continuous layer of modeling material from the support member 230 of the modeling material chamber 226 to the support member 236 of the modeling chamber 228, for example. . However, in other examples, the build material supplier 242 may instead be a component of the system 200 and attached to or on the housing 202.

  Returning to FIG. 2 a, a fixing member 252 may be attached to the bottom surface of the central housing portion 206 of the housing 202. Alternatively or additionally, the securing member may be attached to the side housing portion 204 and / or the back housing portion 208. In FIG. 2a, the fixing member 252 extends elongated along the longitudinal direction of the central housing portion 206, but in other examples, the fixing member 252 may have other configurations. In some examples, a plurality of individual fixation members may be provided at various points along the longitudinal direction of the bottom surface of the central housing portion 206.

  Returning to FIG. 2 b, a fixing member 254 may be attached to the upper surface of the housing 216. Alternatively or additionally, the securing member may be attached to any other surface of the housing 216, including any of the four sides. In FIG. 2b, the securing member 254 extends elongated along the longitudinal direction of the housing 216, but in other examples, the securing member 254 may have other configurations. In some examples, a plurality of individual securing members 254 may be provided at various points along the length of the upper surface of the housing 216.

  In order to enable the additive manufacturing system 200 to receive the modeling module 214 in the receiving volume 212 and to removably couple the additive manufacturing system 200 to the modeling module 214, the fixing member 252 and the fixing member 254 are one May be combined. As shown, the shaping module 214 may be received into the receiving volume 212 from the side or from approximately the side, for example from the horizontal or generally horizontal direction. The fasteners 252 and 254 may be magnetic fasteners, mechanical fasteners, and / or other types of fasteners.

  If the fasteners 252 and 254 are magnetic fasteners, they can each be magnetic. That is, each of these fixtures may be composed of a suitable material that is subject to force in the presence of a magnetic field and / or that itself generates a magnetic field. Therefore, when the fixture 252 and the fixture 254 are in a sufficiently close state, they are attracted and the modeling module 214 can be fixed to the additive manufacturing system 200. For example, fixtures 252 and 254 may include permanent magnets such as ferromagnetic materials, or antiferromagnetic materials, ferrimagnetic materials, paramagnetic materials, diamagnetic materials, or electromagnets.

  When the fixtures 252 and 254 are mechanical fixtures, one of the fixtures 252 and 254 may be a latch member and the other may be a receiving member. For example, the modeling module 214 can be fixed in the additive manufacturing system 200 by inserting the latch into the receiving member or attaching it to the receiving member.

  When the modeling module 214 is inserted into the receiving volume 212 of the additive manufacturing system 200, the various components of the system, such as drug dispensers, energy sources, heaters, and sensors, may cause the modeling chamber 228 and any modeling therein. In order to be able to act on the material, the cover 222 is intended to be removed.

  2f-2g are simplified perspective views showing an additive manufacturing system after receiving various removable modeling modules, according to some examples. In general, the modeling module can have any length along the x-axis direction or the y-axis direction. For example, as illustrated, the variously sized modeling modules 214a to 214d can have any length along the x-axis direction. For example, in FIG. 2g, a single shaping module 214d has a length along the y-axis that can fill the entire receiving volume 212 when inserted into the system 200. In FIG. 2 f, a plurality of modeling modules 214 a to 214 c having a shorter length along the y-axis direction are arranged in a line along the y-axis direction, and as a whole, they fill the entire receiving capacity 212. . Therefore, in FIG. 2f, the modeling chambers and the supporting members of the modeling modules 214a to 214c may be arranged in a line. Further, FIG. 2f shows different shaped modeling modules, for example, the shaped modules 214a-214c have different lengths.

  FIG. 2h is a simplified perspective view illustrating a removable modeling module 214c for an additive manufacturing system, according to some examples. The build module 214c is shown removed from the system 200 of FIG. 2f. As illustrated, the modeling module 214c is longer than the modeling module 214 of FIGS. 2b to 2e, and therefore has a modeling material chamber 226c that is longer along the y-axis direction than the modeling material chamber 226 of the modeling module 214. Moreover, compared with the modeling chamber 228, it can have the modeling chamber 228c long along the y-axis direction. Although not shown, the modeling module 214d may have various rooms (chambers) extending along the y-axis direction and extending over the entire length of the modeling module 214d.

  Further, although not shown, the width of the shaping module and the various rooms (chambers) along the x-axis direction may also be different.

  In some examples, different configurations of build modules and / or build assemblies may be used. FIG. 3 is a simplified side view illustrating a build assembly 324 of a build module, according to some examples. The housing 216 of FIGS. 2 b-2 c may not only removably receive the build assembly 224, but may also removably receive the build assembly 324. When the build assembly 324 is inside the housing 216, the cover 222 may be removable to expose the build assembly 324 and its build chamber 328.

  By using a handle attached to the side of the build assembly 324, the build assembly 324 can be removed from the housing 216 like a drawer. A further handle may be provided on the surface of the modeling assembly 324. In other examples, the drawer can be removed using automatic means and / or electrical means, for example, when the user makes an input such as pressing a button on the housing 216, build assembly 324, or system. May be opened automatically.

  In FIG. 3, the build assembly 324 has been completely removed from the housing 216. The modeling assembly 324 may include a modeling material chamber 326 and a modeling chamber 328. The modeling material chamber 326 may be below the modeling chamber 328. Thus, for example, the width of the modeling chamber 328 can be increased so that a wider layer of modeling material can be supplied to the modeling chamber 328.

 A support member 330 may be provided in the modeling material chamber 326. In the figure, the modeling material 246 is stored on the upper surface of the support member 330 of the modeling material chamber 326. The support member 330 may have an angle at which the modeling material 246 can slide down due to gravity. A support member 336 may be provided in the modeling chamber 328. On the upper surface of the support member 38 of the modeling chamber 328, a layer 248 of previously deposited modeling material is shown. The previously deposited build material 248 includes a portion 250 that is processed using the additive manufacturing system 200 and cured as part of a three-dimensional object. A piston 338 may be attached to the bottom surface of the support member 336. The piston 338 is driven by the motor 340 and can move the support member 336 along the z-axis. In one example, support members 330 and 336 may be movable along the z-axis. In one example, support members 330 and 336 may have dimensions in the range of about 10 cm × 10 cm to 100 cm × 100 cm. In other examples, support members 330 and 336 may have larger or smaller dimensions.

  For example, one or more build material feeders 332, 384, and to enable the supply or deposition of a continuous layer of build material from the support member 330 of the build material chamber 326 to the support member 336 of the build chamber 328, and 342 may be used. A modeling material supply device 332 such as a rotatable ball, wheel, or roller may be attached to the modeling material chamber 326, for example. The modeling material supplier 332 is driven by a motor 334, rotates, and can move the modeling material 236 as indicated by the bent arrows. A build material supplier 384, such as a conveyor, attached to the build assembly 324 is driven by a motor 382 and can then move the build material 246 upward in the z-axis direction as indicated by the arrows. it can. In another example, the building material supplier 384 may be a rotation system having a blade that moves the building material 246 upward in the z-axis direction when rotated. A build material supplier 342, such as a wiper blade or roller, attached to the build assembly 324 is driven by a motor 344 and moves vertically in the x-axis direction to move the build material 242 to a support member 336 in the build chamber 328. Can be moved to the top. However, in some examples, the build material supplier 342 may instead be a component of the system 200 and attached to or on the housing 202.

  Although not shown, in some examples, any of the build assemblies described herein may use a build material supply with a build material transport that operates with compressed air or hydraulic pressure. Such a modeling material supplier may be driven by a motor.

  In some examples, the build module 214 may include a controller and computer readable medium having functions similar to the controller 256 and the computer readable medium 260 described above. In such an example, the computer readable medium includes, for example, the size of the modeling module 214, the size of each of the various chambers of the modeling module 214, and the modeling material provided and stored in the modeling material chamber of the modeling module 214. Data and / or instructions may be stored that indicate various features of the shaping module 214, such as These data and / or instructions may be stored for access by the controller 256 when the shaping module 214 is inserted into the system 200 to generate a three-dimensional object. In some examples, an input device on a build module having functionality similar to the controller 256 input device described above receives input from the user regarding the type of build material stored in the build module 214. Can do. In some examples, a sensor on the build module 214 can automatically detect the type of build material.

  The additive manufacturing system 200 selectively supplies a coalescing aid to a continuous layer of modeling material provided on one or more support members 236 in one or more modeling chambers 228 described later. 268 may be included. The coalescing aid is a material that can combine and cure the modeling material when an appropriate amount of energy is applied to the combination of the modeling material and the coalescing aid. According to one non-limiting example, a suitable coalescence aid is an ink-based composition comprising carbon black, such as, for example, an ink composition called CM997A commercially available from Hewlett-Packard Company. There is a case. In one example, such an ink may further include an infrared light absorber. In one example, such an ink may further include a near infrared absorber. In one example, such an ink may further include a visible light absorber. Examples of inks that contain a visible light enhancer are dye-based color inks and pigment-based color inks, such as the inks available from Hewlett-Packard Company, called CM993A and CE042A.

  The controller 256 may control the selective supply of coalescing aids to the provided layer of build material according to various instructions including drug supply control data 266 stored on the computer readable medium 260.

  The medicine supplier 268 may be a print head such as a thermal print head or a piezoelectric ink jet print head. The print head may have an array of nozzles. In one example, a print head such as that commonly used in commercially available ink jet printers may be used. In other examples, the drug may be supplied through an ejection nozzle rather than through a printhead. Other supply means may be used.

  If the coalescing aid is in the form of a suitable fluid, such as a liquid, a drug feeder 268 may be used to selectively deliver, eg deposit, the coalescing aid. In some examples, the drug dispenser 268 may be selected to deliver a drop of drug with a resolution between 300 DPI and 1200 DPI, such as 600 dots per inch (DPI). . In other examples, the drug dispenser 268 may be selected to be able to dispense droplets with higher or lower resolution. In some examples, drug dispenser 268 may have an array of nozzles, and drug dispenser 268 may be able to selectively eject drops of fluid through the array of nozzles. In some examples, each droplet may be on the order of about 10 picoliters (pl). However, in other examples, a drug dispenser 268 that can supply larger or smaller droplets may be used. In some examples, a drug supply 268 that can supply variable sized droplets may be used.

  In some examples, drug dispenser 268 may be an integral part of system 200. In some examples, the drug dispenser 268 is not fixed and may be user replaceable, in which case the drug dispenser 268 may be a suitable drug dispenser, such as an interface module of the system 200, for example. It may be possible to removably receive (eg, insertable) into the receiver.

  In the example of FIG. 2a, the medicine supply device 268 has a length in the x-axis direction that covers the entire width of the support member 236 or 336 of the modeling module 214 in the x-axis direction, and forms a so-called page width array configuration. In one example, this may be achieved by an appropriate arrangement of multiple printheads. In other examples, a single printhead with an array of nozzles having a length that spans the width of the support member 236 or 336 may be used. In other examples, drug dispenser 268 may have a shorter length that does not reach the full width of support member 236 or 336.

  The drug supply 268 is mounted on a movable carriage and is movable bi-directionally over the entire length of a series of one or more support members 236 or 336 along the y-axis direction, as indicated by arrow 270. May be configured. This allows a selective supply of coalescing aid over the entire width and length of the support member 236 or 336 in a single pass.

  As used herein, the term “width” generally refers to the shortest dimension in the plane parallel to the x-axis and y-axis shown in FIGS. The term “length” as used in is generally the longest dimension in this plane. However, in some examples, the word “width” may be interchangeable (synonymous) with the word “length”. For example, in some examples, drug dispenser 268 may have a length that spans the entire length of support member 236 or 336, but the movable carriage moves bi-directionally across the width of support member 236 or 336. There is a case.

  In another example, the drug dispenser 268 does not have a length that spans the full width of the support member 236 or 336, but further moves in both directions across the full width of the support member 236 or 336 in the illustrated x-axis. It may be possible. According to this configuration, it is possible to selectively supply the coalescing aid over the entire width and length of the support member 204 using a plurality of passes. However, other configurations, such as a page width array configuration, may allow a three-dimensional object to be created more quickly.

  The coalescing aid supplier 268 may contain a coalescing aid or may be connectable to an independent coalescing aid.

  In some examples, there may be additional coalescing aid feeders such as drug feeder 274. In some examples, the various feeders of system 200 may be located on the same carriage, either adjacent to each other or separated from each other by a short distance. In some examples, each of the two or more carriages may have one or more feeders. For example, each feeder may be placed on its own individual carriage. Any of the additional feeders can have a function similar to that described above with reference to the coalescing aid supplier 268. However, depending on the examples, for example, different drug supply units may supply different coalescence aids.

  System 200 may further include an energy source 272 attached to housing 202. The energy source 272 may be configured to apply energy to the build material and to cure various portions of the build material according to where the coalescing aid is supplied or penetrated. In some examples, the energy source 272 is an infrared (IR) radiation source, a near infrared radiation source, or a halogen radiation source. In some examples, the energy source 272 may be a single energy source that can apply energy uniformly to the build material deposited on the support member 236 or 336. In some examples, energy source 272 may include an array of energy sources.

  In some examples, the energy source 272 is configured to apply energy in a substantially uniform manner across the entire surface of the layer of build material. In such an example, energy source 272 may be referred to as an unfocused energy source. In such an example, energy can be applied to the entire layer at the same time, which can help to increase the rate at which a three-dimensional object can be generated.

  In other examples, the energy source 272 is configured to apply energy in a substantially uniform manner to a portion of the entire surface of the layer of build material. For example, the energy source 272 may be configured to apply energy to an elongated strip of the entire surface of the layer of build material. In such an example, the energy source is moved across the layer of build material, i.e., scanned, so that a substantially equal amount of energy is ultimately applied uniformly across the surface of the build material layer. There is a case.

  In some examples, the energy source 272 may be mounted on a movable carriage.

  In other examples, the energy source 272 may apply a variable amount of energy as it is moved across the layer of build material, for example, according to the drug supply control data 266. For example, the controller 256 may control the energy source so that energy is applied only to the part of the modeling material to which the coalescence aid has been applied.

  In yet another example, the energy source 272 may be a focused energy source such as a laser beam. In this example, the laser beam may be controlled to scan across all or part of the layer of build material. In these examples, the laser beam may be controlled to scan across the layer of build material according to the drug delivery control data. For example, the laser beam may be controlled to apply energy to various portions of the layer supplied with the coalescing aid.

  In some examples, the system 200 may further include a heater or preheater that generates heat to maintain the build material deposited on the support member 236 within a predetermined temperature range. In some cases, the heater has an array of heating devices. Each of the heating devices may be any suitable heating device, for example a heating lamp such as an infrared lamp. The configuration may be optimized so that a uniform heat distribution is provided over the extent of the build material. In order to variably control the local energy density applied to the surface of the build material, each heating device or group of heating devices may have an adjustable current source or voltage source.

  FIG. 4 is a flow diagram illustrating a method 400 for generating a three-dimensional object, according to some examples. This method may be implemented on a computer. In some examples, the illustrated order may be changed, eg, some steps may be performed simultaneously, some steps may be added, or some steps may be omitted. In describing FIG. 4, reference is made to FIGS. 2a, 2e, 3, and 5a-5d. 5a-5d are a series of cross-sectional side views illustrating layers of build material according to some examples.

  At 402, the controller 256 can obtain the drug supply control data 266. The drug supply control data 266 can define various parts, if any, on the building material to which the coalescing aid is to be supplied, for each slice of the three-dimensional object to be generated. The drug supply control data 266 may be supplied from a suitable three-dimensional object processing system that is internal or external to the system 200. In some examples, drug supply control data 266 is generated based on object design data representing a three-dimensional model of the object to be generated and / or from object design data representing various properties of the object. There is a case. The three-dimensional model can define various three-dimensional parts of the object, and the three-dimensional model can be processed by a three-dimensional object processing system to generate various pieces of parallel planes of the three-dimensional model. it can. Each section may define a portion of the layer of individual build material that is to be cured by the additive manufacturing system. Object property data may define various properties of an object such as density, surface roughness, strength, and the like.

  At 404, the computer readable medium on the modeling module 214 determines modeling module data representing various characteristics of the modeling module, such as the type of modeling material used, based on, for example, user input or detection by a sensor, And / or can be stored. As previously mentioned, other features of the shaping module, such as the physical dimensions of the shaping module, may be stored in advance on the computer readable medium.

  At 406, one or more modeling modules 214 can be received by the system 200. The controller 256 of the system 200 can access the computer readable medium of the build module 214 and find the build module data.

  At 408, a layer of building material 276 can be provided, as shown in FIG. 5a. For example, the controller 256 can control the build material supplier 242 to provide a layer 276 over the previously completed layer 248 shown in FIGS. 2e and 5a. The previously completed layer 248 may include a cured portion 250. For purposes of illustration, the completed layer 248 is shown in FIGS. 5 a-5 d, but it is contemplated that steps 408-412 may be used first to produce the first layer 248.

  In some examples, such as when a build assembly 224 is used, the layer 276 may be provided in the following manner. Referring to FIGS. 2e and 5a, the support member 230 of the build material chamber 226 can be moved by the piston 232 in the z-axis direction so that a portion of the stored build material 246 extends beyond the upper edge of the build assembly 224. May be positioned. The support member 236 of the modeling chamber 228 may be positioned in the z-axis direction by the piston 236 in such a way that a predetermined gap is obtained on the layer 248 of the modeling material previously deposited. After that, the modeling material supplier 242 moves vertically in the x-axis direction, and the extended portion of the stored modeling material 246 is poured into a predetermined gap to generate a new layer 276 in the modeling chamber 228. The supplying may be based on data and / or instructions relating to various features of the modeling module stored on the computer readable medium of the modeling module.

  In some examples, such as when a shaping assembly 324 is used, the layer 276 may be provided in the following manner. Referring to FIGS. 3 and 5 a, the support member 330 of the build material chamber 236 is moved by the piston in the z-axis direction so that a portion of the stored build material 246 extends beyond the upper edge of the build assembly 324. May be positioned. The support member 336 of the modeling chamber 328 may be positioned in the z-axis direction by the piston 338 in such a way that a predetermined gap is obtained on the layer 248 of the modeling material previously deposited. Thereafter, build material feeders 332, 384, and 342 may be used to supply layer 276. The stored modeling material 246 can be moved along the arrow in FIG. 3 and poured into a predetermined gap, and a new layer 276 can be generated in the modeling chamber 328. The supplying may be based on data and / or instructions relating to various features of the modeling module stored on the computer readable medium of the modeling module.

  At 410, a coalescing aid 278 can be selectively supplied to one or more portions of the surface of the build material layer 276, as shown in FIG. 5b. The selective supply of coalescing aid 278 is applied to various portions of layer 276 that may be defined by drug supply control data 266 as being cured to form part of the three-dimensional object being produced. In some cases, various patterns are implemented. “Selective supply” means that the coalescing aid may be supplied in various patterns to selected portions of the surface layer of the build material. The pattern may be defined by the drug supply control data 266 or may be determined based on data and / or instructions regarding various features of the shaping module stored on the computer readable medium of the shaping module.

  FIG. 5 c shows the coalescing aid 278 that has penetrated substantially completely into the layer of building material 276, but in other examples, the degree of penetration may be less than 100%.

  At 412, a predetermined level of energy can be temporarily applied to the layer of modeling material 278. In various examples, the energy applied may be infrared or near infrared energy, microwave energy, ultraviolet (UV) light, halogen light, ultrasound, and the like. Depending on the temporary application of energy, the coalescing aid 278 can be supplied or the various parts permeated by the coalescing aid 278 can be heated and coalesced above the melting point of the build material. Upon cooling, the combined part becomes a solid and forms part of the three-dimensional object being generated. As noted above, one such portion 250 may be generated in the previous iteration. The heat absorbed during the application of energy propagates to the previously cured portion 250 and may heat a portion of that portion 250 above its melting point. This action helps to form a portion 280 having a strong interlayer bond between adjacent layers of cured build material, as shown in FIG. 5d.

  After the modeling material layer is processed as described above, a new modeling material layer can be provided on the previously processed modeling material layer. Thus, the previously processed layer of modeling material serves as a support means for the subsequent layer of modeling material. Thereafter, by repeating the processing from block 408 to 412, a three-dimensional object can be generated one layer at a time.

  Further, at some point between blocks 408 and 412, yet another modeling module 214 may be accepted by the system 200, as in block 406. That is, the method 400 repeats blocks 408 through 412, but the method 200 allows the system 200 to perform multiple print jobs at once based on different three-dimensional objects on different modeling modules 214. 400 parallel instances may be implemented. In another example, immediately after the first instance of the method 400 is completed and a three-dimensional object is generated, the second instance of the method 400 is performed according to blocks 408 to 412, whereby the first cubic A second three-dimensional object may be generated immediately after the original object is completed, with little or no delay.

  In addition, in some cases, there is only a slight time delay, or no delay time, even if the build module 214 requires cleaning or refilling during the generation of the three-dimensional object. May not. For example, if a modeling module 214 requires cleaning or refilling, the system 200 may remove the modeling module 214 from the system 200 while continuing to generate other three-dimensional objects in other modeling modules 214. . Further, according to the design of the build module 214, such as a fully functional build system including, for example, the motors 234 and 240 of FIGS. 2d-2e, or the motors 334, 340, 344, and 382 of FIG. The modeling module 214 can be quickly and easily cleaned. For example, the housing 216 may help prevent the build material from leaking into an undesirable location in the build module 214. In addition, the modeling module 214 may be inserted into a cleaning device, which, for example, operates while operating the motor so that the modeling material can be shaken off the various components of the modeling module 214. Various parts of the module 214 may be automatically cleaned. In some cases, various manual steps may be performed during cleaning, for example, while operating a motor.

  All of the features disclosed in this specification (including the appended claims, abstract and drawings) and all of the various steps of the disclosed method or process are at least one of such features and / or steps. It may be implemented in any combination except for combinations in which the parts are mutually exclusive.

  In the above description, numerous details are set forth in order to provide a thorough understanding of the subject matter disclosed herein. However, the examples may be practiced without some or all of these details. Some examples may include modifications and variations from the details set forth above. The appended claims are intended to cover such modifications and changes.

Exemplary embodiments of the present invention are listed below:
1. A modeling module,
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, wherein the modeling material chamber is below the modeling chamber, and the modeling chamber receives a continuous layer of the modeling material from a modeling material supplier Including a modeling room and
The modeling module can be removably inserted into a modeling receiver of an additive manufacturing system, whereby the additive manufacturing system cures a portion of the continuous layer received on the movable support member. A modeling module that can.
2. 2. The modeling module according to 1, further comprising the modeling material supplier for providing a continuous layer of the modeling material from the modeling material chamber onto the support member of the modeling chamber.
3. 3. The modeling module according to 2, further comprising a motor for driving the modeling material supplier.
4). The modeling module according to 1, wherein the housing includes a first fixture for coupling with the second fixture of the modeling module and fixing the modeling module in the housing.
5. 2. The modeling module according to 1, wherein the modeling module is configured to be removably inserted from the side into the modeling receiver.
6). A modeling module,
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, wherein the modeling chamber includes a movable support member for receiving a continuous layer of the modeling material from a modeling material supplier; and
A computer readable medium provided in the housing, wherein the computer readable medium includes modeling module data representing characteristics of the modeling module;
The modeling module can be removably inserted into a modeling volume of the additive manufacturing system, whereby the additive manufacturing system cures a portion of the continuous layer received on the movable support member. A modeling module that can.
7). The controller of the additive manufacturing system is
Controlling at least one of providing the modeling material to the modeling room by the modeling material supplier and selectively supplying the coalescing aid to the modeling material by the drug supplier based on the modeling module data The modeling module according to claim 6, configured as described above.
8). The modeling module according to 6, wherein the features include the type of modeling material to be held in the modeling chamber.
9. The modeling module according to 8, further comprising a sensor for detecting the type of the modeling material.
10. The modeling module of claim 6, wherein the features are received as input from a user on the computer readable medium.
11. A modeling module for an additive manufacturing system, wherein the modeling module is
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, including a movable support member for receiving a continuous layer of the modeling material from a modeling material supplier; and
The modeling module can be removably inserted into the modeling volume of the additive manufacturing system simultaneously with another such modeling module, whereby the additive manufacturing system is received on the movable support member A modeling module capable of curing a part of the continuous layer.
12 The modeling module according to 11, wherein the modeling material supplier is a part of the additive manufacturing system in which the modeling module can be removably inserted.
13. The modeling module according to 11, wherein the modeling material chamber includes a movable support member for holding the modeling material.
14 The modeling module according to 11, wherein the modeling module is configured to be removably inserted into the modeling capacity from the side.
15. An additive manufacturing system for removably receiving the modeling module according to claim 1.

Claims (15)

A modeling module,
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, wherein the modeling material chamber is below the modeling chamber, and the modeling chamber receives a continuous layer of the modeling material from a modeling material supplier Including a modeling room and
The modeling module can be removably inserted into a modeling receiver of an additive manufacturing system, whereby the additive manufacturing system cures a portion of the continuous layer received on the movable support member. A modeling module that can.   The modeling module according to claim 1, further comprising the modeling material supplier for providing a continuous layer of the modeling material from the modeling material chamber onto the support member of the modeling chamber.   The modeling module according to claim 2, further comprising a motor for driving the modeling material supplier.   The modeling module according to claim 1, wherein the housing includes a first fixture for coupling with a second fixture of the modeling module and fixing the modeling module in the housing.   The modeling module according to claim 1, wherein the modeling module is configured to be removably inserted into the modeling receiver substantially from the side. A modeling module,
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, wherein the modeling chamber includes a movable support member for receiving a continuous layer of the modeling material from a modeling material supplier; and
A computer readable medium provided in the housing, wherein the computer readable medium includes modeling module data representing characteristics of the modeling module;
The modeling module can be removably inserted into a modeling volume of the additive manufacturing system, whereby the additive manufacturing system cures a portion of the continuous layer received on the movable support member. A modeling module that can. The controller of the additive manufacturing system is
Controlling at least one of providing the modeling material to the modeling room by the modeling material supplier and selectively supplying the coalescing aid to the modeling material by the drug supplier based on the modeling module data The modeling module according to claim 6, configured as described above.   The modeling module according to claim 6, wherein the features include a type of the modeling material to be held in the modeling chamber.   The modeling module according to claim 8, further comprising a sensor for detecting the type of the modeling material.   The modeling module of claim 6, wherein the features are received as input from a user on the computer readable medium. A modeling module for an additive manufacturing system, wherein the modeling module is
A housing;
A modeling material chamber provided in the housing to hold the modeling material;
A modeling chamber provided in the housing, including a movable support member for receiving a continuous layer of the modeling material from a modeling material supplier; and
The modeling module can be removably inserted into the modeling volume of the additive manufacturing system simultaneously with another such modeling module, whereby the additive manufacturing system is received on the movable support member A modeling module capable of curing a part of the continuous layer.   The modeling module according to claim 11, wherein the modeling material supplier is a part of the layered modeling system in which the modeling module can be removably inserted.   The modeling module according to claim 11, wherein the modeling material chamber includes a movable support member for holding the modeling material.   The modeling module according to claim 11, wherein the modeling module is configured to be removably inserted into the modeling capacity from the side.   An additive manufacturing system for removably receiving the modeling module according to claim 1.

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